Base for electric lamps and similar devices and method of manufacture



Dec. 14, 1943. J. J. MALLOY BASE FOR ELECTRIC LAMPS AND SIMILAR-DEVICES AND METHOD OF MANUFACTURE Filed June 20, 1942 lnyentor: John J. MalLo H, all-6M His A't'torneg.

Patented Dec. 14, 1943 BASE FOR ELECTRIC LAMPS AND SIMILAR DEVICES AND METHOD MANUFACTURE John J. Malloy, Cleveland Heights, Ohio, assignor to General Electric Company, a corporation 01' New York Application June 20, 1942, Serial No. 447,818

26 Claims.

This invention relates to basing the bulbs or envelopes of electrical devices, including incandescent lamps as well as discharge devices of various kinds. The invention aims at facilitating and cheapening the attachment of the base to the electrical device or bulb, and at avoiding the necessity for soldering in making electrical connections. The invention is hereinafter explained with particular reference to bases of the Edison and kindred screw and center contact types, though it is also applicable to bases.

of very different types from this, such as the doubleend-contact bayonet type, for example.

Other features and advantages of the invention will become apparent from the description of species and forms of embodiment, and from the drawing.

In the drawing, Fig. 1 is a longitudinal sectional view of an Edison base somewhat modified' for the purposes of the invention, illustrating an initial stage in it application to an incandescent lamp, part of which is also shownthe section being taken as indicated 'by the line the ordinary commercial type of Edison screw I base.

and arrows in Fig. 2. Fig. 2 is a fragmentary side View of the base, taken approximately at right angles to Fig. 1, illustrating the same stage of the operation. Fig. 3 is a fragmentary tilted or perspective view of the base, showing a further stage of the operation. Fig. 4 is a view similar to Fig. 3 showing the connection of a leadwire to the center contact of the base completed; and Fig. 5 is a fragmentary sectional view, taken as indicated by the line and arrows 5-5 in Fig, 4, on a larger scale.

Fig. 6 is a fragmentary perspective view of an Edison screw base having its end or center contact modified for the purposes of my invention,

illustrating an initial stage in .the connection of a leadwire to this contact; Figs. '1 and 8 are similar views illustrating subsequent stages of the operation; Fig. 9 is a similar view showing the operation completed; and Fig. 10 is a view similarto Fig. 9 showing a somewhat different center contact.

Fig. 11 is a tilted or perspective view of another modified form of center contact part suitable for the purposes of my invention, on a relatively large scale; Fig. 12 is a longitudinal sectional view of an Edison type base embodying iiis center contact; and Fig. 13 is a similar view of this base applied to an incandescent lamp, part of which is also shown.

Fig. 14 is a view similar to Fig. 13 illustrating the application of the part shown in Fig. 11 to Fig. 15 is a side viewof an Edison type base illustrating a mode of connecting a lead wire to its .screw shell, which is partly broken out and in section; and Fig. 16 is a side view at right angles to Fig. 15.

Figs. 1-5 illustrate the application of my invention to an Edison screw base structure A comprising a sheet metal screw shell or skirt 20 with an insulative body or web 2| (such as glass) at one end thereof. This end-body 2| is shown as of frusto-conical conformation where it projects through the end opening of the screw shell. On the outer side of the insulative body 2| is exposed an end-contact 22, here shown as a sheet metal disc medially apertured at 24 and formed as the enlarged outer head or flange of a rivet-like center contact eyelet whose sleeve portion 25 is also expanded or flanged at 'its inner end to anchor the disc to the insulative base-end 2|, in which said sleeve is molded or embedded. Basing cement 26 maybe used to assist in fixing the base A- on the neck of the lamp bulb B, as usual.

The base-end 2| has an aperture 21 therethrough for the passage of a lead wire 30 from This laterally offset or raised conformation 3| maybe formed either previou to molding the Q contact 22 into the insulation 2|, or subsequently.

After the cement 26 has been applied to the base A and the base has been placed on th neck of the bulb B with the lead wire 30 passed out through the opening 21 as shown in Fig. 1, the

wire 30 is bent aside (counterclockwise) under the edge of the raised disc area 3| and around the disc anchorage 25, being forcibly crowded under the disc as far as possible-with a resulting lifting of the fiexile disc margin from the surface of the base-end2l as shown in Fig. 3, and a consequent firm wedging or clamping fast of the wire. The wire 30 may bebent or wrapped around the anchorage 25 to any angular extent deemed advisable-as shown in Fig. 3, about 270 to 300. The free wire beyond the edge of the disc 22 having been cut off, and the end 32 preferably pushed in under the disc, the lifted disc margin may be forced or flattened down against the" base-end 2! outside the wire 3%, so as to hold the wire more firmly and secure it against displacement outward, as shown in Fig. 5. While any portion of the fiexile disc margin that is thus crowded down on the wire 3&3 and against the base-end 2i will clamp the wire fast and retain it under the disc, it is preferable to flatten down the margin into contact with the baseend 2! all the way around, so that the disc looks just as if it had never been lifted at all. As the lead wire 39 need not for ordinary lamps be or more than about 12 mil diameter, the slight annularly extending elevation of the disc over the wire as indicated in Figs. 4 and 5 is not noticeable, and can barely be observed.

The base Ac illustrated in'Figs. 6-10 differs from the base A in Figs. l5 in that the baseend aperture 23a for the lead wire 3E3 coincides with the aperture 25 in the midst of the contact 22 itself, just as in ordinary commercial Edison bases. Unlike the center contacts of ordinary bases, however, the contact disc or flange 22 has a notch or slit 38 inward from its periphery, preferably to and even into the flaring end of the sleeve 25, and the margin of the sheet metal at one (counterclockwise) side of the slit 33 is raised or turned up at 83:: above that at the other side of this slit. After the base Ac has been placed on the neck of the bulb with the lead wire to passed out throughv the base-end and contact apertures 27c and 25 (as well as through the sleeve 25) the wire 36 is bent aside and engaged through the slit 83 and bent on around the anchorage 25 and crowded under the disc, lifting the disc margin from the base-end 2i and clamping the wire under the disc as illustrated in Fig. 8-and very much as in Fig. 3-3. By subsequently forcing or flattening down the raised disc margin outside the wire 3! (preferably all the way around) as in Figs. 9 and ill, the wire is clamped more firmly and secured against outward displacement, as described above in connection with represents the actual removal of a narrow width of the metal, while in Fig. it it is a more out or shear of the sheet metal.

Fig. 11 illustrates a center contact part 85 that may be used for the purposes of my irwention.

The tubular sleeve 25?) of this contact is externally shouldered by enlargement at 35 near its outer end 22b, and this headed over flange or disc portion 22b is reduced in radial width as compared with those in Figs. 1-10, so that it is nothing like coextensive with the flat top surface of the base-end ill. Thus the part 36 as a whole is in effect a hollow plug or rivet with its outer end enlarged at 3&3 as well as at 22?). The upper end or the part is slit or notched diametrally at 3th through opposite sides or its flange or head 22?; and into the enlarged sleeve portion 35 behind this flange. As shown in Fig. 12, the sleeve 25b 01 part 35 is fined in the aperture 27b of the base-end 2i with its shoulder lit engaging the top surface thereof, and with its lower end expanded or headed at St to anchor it. In practice, it may either be molded into the iusulative body '2! during the manufacture of the base Ab, or may be inserted and riveted in after the base Ab has been manufactured. After applying the base Ab to a lamp bulb B with the lamp lead wire 30 passed through the sleeve b, as shown in Fig. 13,- the wire may be bent aside and engaged through one of the notches 33b and bent around the sleeve portion 55 behind the head flange 22b, thus directly connecting and securing the lead to the center contact. If the size of the wire 30 is suflicient, this will result in temporarily and elastically springing up the flange 2% so as to clamp the bent wire 30 securely beneath it. In any case, the outer margin of this disc or flange 222) may be permanently forced or pressed down on and around the wire as also shown in Fig. 13, so as to clamp it more firmly and secure it against outward displacement.

The construction illustrated in Fig. 14 is like that in Fig. 13 except that an ordinary Edison base Ac is shown with the usual center contact eyelet 22c, and the part 35 such as shown in Fig. 11 is riveted through the eyelet sleeve 25, instead of directly into the insulative end -'body 2! as in Fig. 13. Accordingly, the wire 30 bent around the part 35 is clamped against the disc head of the eyelet 22c and electrically connected thereto,

so that the parts 22 and 35 together serve as thecenter contact. a

While one lead 39 is brought out through the insulative end-body 2i and secured to the end or center contact as above described, the other lead d5] may be retroverted to extend back along a the bulb neck and out past the edge of the screw shell 21?, to which it may be soldered or otherwise connected in any usual or preferred manner. as

. Figs. i and 5. As shown in Fig. 9, the slit a indicated at ll in Figs. 1 and 13. As shown in Figs. 15 and 18, this is done by means of a tongue or ear portion (32 sheared out of the sheet metal of the screw shell 29 and bent back on the end. portion 13 of the lead wire, which extends out through a notch in the screw shell at M alongside the ear 32, and is bent aside to lie behind the car when the latter is bent back. Thus the wire end portion is clamped by the ear A2 against the exterior of the screw shell 26.

as already mentioned, the end body 2i may be of gla s or other lnsulative material, such as molded plastic. The screw shell 26 and end contact 22, 22b, 22c may be of sheet metal usually used for such parts of lamp bases, particularly brass, or even soft sheet iron or mild steel. The lead wires 39, ill may likewise be of metals usugllly used for lamp leads, such as copper or soft rob.

What I claim as new and desire to secure by Letters Patent of the United States is:

l. A base construction oi the character described comprlslng an apertured base end, a fiangedinetal eyelet having its sleeve portion fused in said base end, and a lead wire extending out through said base end aperture and bent around the sleeve portion of said eyelet under its said flange 2.44. base construction of the character described comprising an apertured base end, a metal sleeve secured to said base and at its aperture and having a slit flange adjacent said base and. and a lead wire extending out through said base end aperture and sleeve and the slit of the flange, and bent around the'sleeve under said flange.

3. a base construction of the character described comprising an apertured base end, a flexible sheet metal disc locally anchored to said base end, and a lead wire extending out through the base and aperture and bent aside herefrom under the disc, a flexile portion of the disc being crowded down on the wire to clamp it fast.

4. A base construction of the character described comprising an apertured base end, a flexslit being crowded against the base end to retain the wire under the disc.

5. A base construction of the character described comprising an apertured base end, a flexible sheet metal disc medially anchored to said base end and apertured substantially in correspondence with the discaperture, and also slit inward from its periphery, and a lead wire extending out through the base end and disc apertures and through the slit of the disc under the latter, and clamped fast thereby.

6. A base construction of the character described comprising an apertured base end, a flexible sheet metal disc locally anchored to said baseend, and a lead wire extending out through the base end aperture and bent aside therefrom under the disc adjacent its anchorage, a flexile marginal portion of the disc, being crowded against the base end outside the wire.

base end, and having a slit flange adjacent said base end. 1

14. In a base of the character described, the

combination with an apertured base end of a metal eyelet having a sleeve portion fixed in said base end, and having a flange adjacent said base end, and slit through said flange into said sleeve portion.

15. In a base of the character described, the combination with an apertured base end of a flexible sheet metal contact disc at theouter side of said base end locally anchored to said '7. A base construction of the character described comprising an apertured base end with a correspondingly apertured end contact thereon, a lead wire extending out through the apertures of said base end and end contact, and a plug in said base aperture securing said lead-wire in electrical connection with said end contact.

8. A base construction of the character described comprising an apertured base end with a correspondingly apertured end contact thereon, a hollow plug in said base aperture, and a lead wire extending out through said hollow plug and secured thereby in electrical connection with said end contact.

9. A base construction of the character described comprising an apertured base end with a correspondingly apertured end contact thereon, a hollow plug in said base aperture engaged with said end contact and enlarged at its outer end, and a lead wire extending out through said hollow plug and bent around the same behind its end enlargement aforesaid.

10. A base construction of the character described comprising an apertured base end with a. correspondingly apertured end contact thereon, a lead wire extending out through the apertures of said base end and end contact, and a. rivet riveted through the base and end contact apertures, and directly securing said lead wire to said end contact.

11. A base construction of the character described comprising an apertured base end with a correspondingly apertured end contact thereon, a hollow rivet riveted through the base and end contact apertures and headed over at its outer end, and a lead wire extending out through said hollow rivet bent around the latter under its head, and clamped thereby against said end contact.

12. In a base of the character described, the combination with an apertured base endof a metal sleeve mounted ons'ald base end around its aperture and having a slit flange adjacent said base end.

13. In a base of the character described, the combination with anapertured base end of a metal eyelethaving a sleeve portion fixed in said base end and slit outward from adjacent the base end aperture to the disc periphery, at least a portion-of the lit extending across the base end surface which lies behind the said disc.

16. In a base of the character described, the combination with an apertured base end of a flexible sheet metal contact disc at'the outer side of said base end medially anchored to said base end and apertured substantially in correspondence with the base end aperture, and also slit inward from the disc periphery, at least a portion of the slit extending across the base end surface which lies behind the said disc.

' 1'7. In a base of the character described, the combination with an apertured base end of a flexible sheet metal contact disc at the outer side of said base end apertured and anchored to said base endsubstantially atthe base end aperture, and slit inward from the disc periphery toward the said disc aperture, at least a portion of the slit extending across the base end surface which lies behind the said disc.

8. In a base of the character described, the combination with an apertured base end and a correspondingly apertured end contact thereon, of a hollow plug fixed in said base aperture and enlarged at its outer end, the said enlarged outer 19. In a base of the character described, the

combination with an apertured base end and a correspondingly apertured end contact thereon, of a hollow rivet extending through the base and end contact apertures and headed'over at its outer end, the said'headed' outer end of the rivet being spaced from the surface of said end contact.

20. In a base of the character described, the

combination with an apertured base end and a A correspondingly apertured end contact thereon, of a shouldered hollow rivet-riveted through the base and end contact apertures, and having its shouldered end flanged over and notched through the flange, the said flange being spaced fsom the surface of said end contact.

21. A method of connecting a lead wire to a sheet metal contact disc locally anchored to an apertured base end, which method comprises passing the lead wire out through the base end aperture and bending it aside therefrom and crowding it under the disc.

22. A method of connecting a lead wire to a sheet metal contact-disc locally anchored to an apertured/ base end, which method comprises passing thelead wire out through the base end aperture and bending it aside therefrom under said disc, and forcing down the sheet metal of the disc on the wire to clamp it fast.v

23. A method of' connecting a lead wire to'an apertured sheet metalcontact disc locally anchored to an apertured base end and also slit inward from its periphery, which method coinprises passing the lead wire out through the base end and disc apertures, bending said lead wire aside and engaging it through the disc slit, and crowding it under the disc between the same and the base end.

24. A method of connecting a lead wire to an apertured sheetmetal contact disc locally anchored to an apertured base end and also slit inward from its periphery, which method comprises passing the lead wire out through the base end and disc apertures, bending said lead wire aside and engaging it through the disc slit, and forcing down the margin of the flange outside the lead wire against the base end to retain the lead wire under the flange.

25. A method of connecting a lead wire to a contact on an apertured base end, said contact comprising a metal sleeve secured to said base end at its aperture and having a flange adjacent said base end that is slit inward from its periphcm, which method comprises passing the lead wire out through said base end aperture and said metal sleeve, bending said lead Wire aside and engaging it through the slit of the flange, and bending it around the sleeve under the flange,

26. A method of connecting a lead wire to a contact on an apertured base end, said contact comprising a metal sleeve secured to said base end at its aperture and having a flange adjacent said base end that is slit inward from its periphery, which method comprises passing the lead wire out through said base, end aperture and said metal sleeve, bending said lead wire aside I and engaging it through the slit of the flange, and forcing down the margin of the flange outside the lead wire against the base end to retain the lead wire under the flange.

JOHN J. MAJLLOY. 

